Low plate-out polycarbonates

ABSTRACT

Polycarbonate resins are chain-terminated with a group selected from those of the formula: ##STR1## wherein R 1 , R 2  and R 3  are each independently selected from the group consisting of hydrogen, halogen, hydrocarbyl of from 1 to 12 carbon atoms, inclusive; and halogen-substituted hydrocarbyl of 1 to 12 carbon atoms, inclusive; R 1  is attached to a ring carbon atom at one of the 4, 5 or 6 positions; and R 2  and R 3  when taken together represent the divalent moiety of formula: --CH═CH 2  --CH 2  ═CH-- 
     which effectively creates an additional fused aromatic ring structure. The resins exhibit a low plate-out when processed thermally.

This is a division of copending application Ser. No. 136,664, filed12/2287.

BACKGROUND OF THE INVENTION

1. Field of The Invention

The invention relates to aromatic carbonate polymers of controlledmolecular weight and more particularly relates to such polymersend-capped with a class of aromatic carboxylic acids or equivalent acidchlorides.

2. Brief Description of the Prior Art

It is known that in certain procedures of producing aromatic carbonatepolymers from dihydric phenols and a carbonate precursor such asphosgene small amounts of certain weight regulators or chain terminatorscan be used to provide end or terminal groups on the carbonate polymerand thereby control the molecular weight of the polycarbonate. Suchmaterials include phenol and p-tertiary-butylphenol.

The prior art also disclosed several other types of compounds that actas chain terminators for the carbonate polymers. Thus, U.S. Pat. No.3,085,992 discloses alkanol amines as chain terminators; U.S. Pat. No.3,399,172 teaches imides as chain terminators; U.S. Pat. No. 3,275,601discloses that aniline and methyl aniline function as chain terminatorsin the interfacial polymerization process for producing polycarbonates;and U.S. Pat. No. 4,001,184 discloses primary and secondary amines asmolecular weight regulators for polycarbonate. Furthermore, U.S. Pat.No. 3,028,365 discloses that aromatic amines and other monofunctionalcompounds can be used to control or regulate the molecular weight of thepolycarbonates, thereby forming aryl carbonate terminal groups. Aromaticpolycarbonates having carbonate end groups are disclosed in U.S. Pat.No. 4,111,910. These polycarbonates are prepared using a terminatingamount of ammonia, ammonium compounds, primary cycloalkyl, aliphatic oraralkyl amines and secondary cycloaklkyl, alkyl or aralkyl amines.

However, according to Schnell, Chemistry and Physics of Polycarbonates(1964), page 183, ammonium hydroxide and amines saponify polycarbonatesback to the monomers, i.e., bisphenol A. This is supported by Bolgianoin U.S. Pat. No. 3,223,678 wherein he indicates that small amounts ofamines such as monoethanolamine and morpholine break or degradepolycarbonates into lower molecular weight polycarbonates. Thus, thisarea of chemistry is generally not very well understood and is one wherethe empirical approach is still generally the method used to determinewhether a particular compound or class of compounds will function aseffective chain terminators or terminal groups in polycarbonate. Thisarea is yet further complicated by the fact that, even though aparticular compound may be a chain terminator, its presence as aterminal group in the polycarbonate polymer may adversely affect thephysical properties of the polycarbonate or molding compositions ofpolycarbonates.

A more recent improvement in the prior art is represented by the use ofaroyl halides to terminate polycarbonate resin chains; see U.S. Pat.4,448,953 to Rosenquist, et al. However, many other improvements aresought over prior art methods for polycarbonate chain termination. Forexample, the use of phenols as chain terminators in the preparation ofpolycarbonates leads to the formation of significant levels of thecorresponding diaryl carbonates as contaminants. Because of thevolatility of these diaryl carbonates, they "plate out" during thermalprocessing onto the molds and processing equipment, i.e.; they condenseon the surfaces of the molds, the processing equipment and also onto thesurface of the molded article itself.

We have now found that the use of certain carboxylic acids and acidchlorides as terminators in the preparation of polycarbonates affordsresins with lower plate-out. The use of these low plate-out resins willreduce molding down time, thus affording higher productivity of a givenresin processing line.

In addition, mixtures of various carboxylic acids can be used to finetune the properties of the resin. For example, stearic acid may be usedwith benzoyl chloride to afford a low plate-out resin with improvedrelease properties. Other advantages of the invention will be describedbelow.

SUMMARY OF THE INVENTION

The invention comprises an aromatic polycarbonate resin having a polymerchain terminated with a monovalent group of the formula: ##STR2##wherein R₁, R₂, and R₃ are each independently selected from the groupconsisting of hydrogen, halogen, hydrocarbyl having from 1 to 12 carbonatoms, inclusive and halogen substituted hydrocarbyl of 1 to 12 carbonatoms, inclusive; R, is attached to a carbon atom at one of the ringpositions 4, 5 or 6; and R₂, and R₃ when taken together represent thedivalent moiety of the formula:

--CH═CH--CH.CH--

which effectively creates an additional fused aromatic ring structure.Preferably R₂, and R₃ are each hydrogen and R₁ is selected from thegroup consisting of halogen, alkyl of 1 to 8 carbon atoms, inclusive andalkaryl; most preferably chlorine, methyl, t-butyl, octyl or p-cumyl.

The polymers of the invention are useful as thermoplastically moldableresins, having a reduced quantity of many plate-out disadvantages.

The term "halogen" is used herein in its normal sense as embracive ofchlorine, bromine and iodine.

The term "hydrocarbyl" as used herein means the monovalent moietyobtained upon removal of a hydrogen atom from a parent hydrocarbon.Representative of hydrocarbyl are alkyl of 1 to 12 carbon atoms,inclusive, such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl,octyl, nonyl, undecyl, decyl, dodecyl and the isomeric forms thereof;cycloalkyl of 3 to 8 carbon atoms, inclusive such as cyclopropyl,cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl and thelike; alkyl substituted cycloalkyl of 4 to 12 carbon atoms, inclusive,such as 2-methylcyclopropyl, 3,4-dimethylcyclohexyl; aryl of 6 to 10carbon atoms such as phenyl, naphthyl; aralkyl of 7 to 10 carbon atoms,inclusive, such as benzyl, phenethyl, phenpropyl, phenbutyl and thelike; alkaryl of 7 to 10 carbon atoms, inclusive, such as methylphenyl,ethylphenyl, propylphenyl, butylphenyl and the like.

The term "halogen substituted hydrocarbyl" as used herein meanshydrocarbyl as defined above wherein one or more hydrogen atoms havebeen replaced with a halogen atom.

The compositions of the invention are useful for injection molding ofcomplex parts such as tool

The compositions of the invention are useful for injection molding ofcomplex parts such as tool housing, parts for automobile bodies, and thelike.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

The aromatic carbonate polymers employed in the practice of thisinvention are thermoplastically moldable carbonate homopolymers ofdihydric phenols, carbonate copolymers of two different dihydric phenolsor copolymers of such dihydric phenols with glycols, e.g., ethyleneglycol or propylene glycol.

These polycarbonates and their preparation are known in the art and aredescribed, for example, in U.S. Pat. Nos. 3,028,365; 3,334,154;3,275,601 and 3,915,926, all of which are incorporated herein byreference. Generally, such aromatic carbonate polymers are prepared byreacting a dihydric phenol with a carbonate precursor. The dihydricphenols employed are known, and in which the reactive groups are the twophenolic hydroxyl groups. Some of these are represented by the generalformula: ##STR3## wherein A is a divalent hydrocarbon radical containingfrom 1 to about 15 carbon atoms; a substituted divalent hydrocarbonradical containing from 1 to about 15 carbon atoms and substituentgroups such as halogen; ##STR4## wherein each X is independentlyselected from the group consisting of hydrogen, halogen, and amonovalent hydrocarbon radical such as an alkyl group of from 1 to about8 carbon atoms, an aryl group of from 6-18 carbon atoms, an aralkylgroup of from 7 to about 14 carbon atoms, an alkaryl group of from 7 toabout 14 carbon atoms, an oxyalkyl group of from 1 to about 8 carbonatoms, or an oxyaryl group of from 6 to 18 carbon atoms; and wherein mis zero or 1.

Typical of some of the dihydric phenols that can be employed in thepractice of the present invention are bis-phenols such as(4-hydroxyphenyl)methane, 2,2-bis(4-hydroxyphenyl)propane (also known asbisphenol A), 2,2-bis(4-hydroxy-3-methylphenyl) propane, 4,4-bis(4-hydroxyphenyl)heptane, 2,2-bis(4-hydroxy-3,5-dichlorophenyl)propane,2,2-bis(4-hydroxy-3,5-dibromophenyl) propane; dihydric phenol etherssuch as bis(4-hydroxyphenyl)ether, bis(3,5-dichloro-4-hydroxyphenyl)ether; dihydroxydiphenyls such as p,p'- dihydroxydiphenyl,3,3'-dichloro-4,4'-dihydrox-ydiphenyl, etc.; dihydroxyaryl sulfones suchas bis(4-hydroxyphenyl) sulfone,bis(3,5-dimethyl-4-hydroxyphenyl)sulfone, dihydroxy benzenes,resorcinol, hydroquinone, halo- and alkyl-substituted dihydroxy benzenessuch as 1,4-dihydroxy-2,5-dichlorobenzene,1,4-dihydroxy-3-methylbenzene, etc.; and dihydroxy diphenyl sulfides andsulfoxides such as bis(4-hydroxy-phenyl)sulfide andbis(4-hydroxyphenyl)sulfoxide,bis(3,5-dibromo-4-hydroxyphenyl)sulfoxide. A variety of additionaldihydric phenols are available and are disclosed in U.S. Pat. Nos.2,999,835; 3,028,365 and 3,153,008; all of which are incorporated hereinby reference. It is, of course, possible to employ two or more differentdihydric phenols or a combination of a dihydric phenol with glycol.

The carbonate precursor can be either a carbonyl halide, adiarylcarbonate or a bishaloformate. The carbonyl halides includecarbonyl bromide, carbonyl chloride, and mixtures thereof. Thebishaloformates suitable for use include the bishaloformates of dihydricphenols such as bischloroformates of 2,2-bis(4-hydroxyphenyl)-propane,2,2-bis(4-hydroxy-3,5- dichlorophenyl)propane, hydroquinone, and thelike, or bishaloformates of glycols such as bishaloformates of ethyleneglycol, and the like. While all of the above carbonate precursors areuseful, carbonyl chloride, also known as phosgene, is preferred.

Also included within the scope of the present invention are the highmolecular weight thermoplastic randomly branched polycarbonates. Theserandomly branched polycarbonates are prepared by coreacting apolyfunctional organic compound with the aforedescribed dihydric phenoland carbonate precursor. The polyfunctional organic compounds useful inmaking the branched polycarbonates are set forth in U.S. Pat. Nos.3,635,895 and 4,001,184, which are incorporated herein by reference.These polyfunctional compounds are generally aromatic and contain atleast three functional groups which are carboxyl, carboxylic anhydride,haloformyl or mixtures thereof. Some nonlimiting examples of thesepolyfunctional aromatic compounds include trimellitic anhydride,trimellitic acid, trimellityl trichloride, 4-chloroformyl phthalicanhydride, pyromellitic acid, pyromellitic dianhydride, mellitic acid,mellitic anhydride, trimesic acid, benzophenonetetracarboxylic acid,benzophenonetetracarboxylic anhydride, and the like. The preferredpolyfunctional aromatic compounds are trimellitic anhydride ortrimellitic acid or their haloformyl derivatives. Also included hereinare blends of a linear polycarbonate and a branched polycarbonate.

The instant invention is directed to novel carbonate polymers having asterminal or end groups particular monovalent moieties of the formula:##STR5## wherein R₁, R₂ and R₃ have the meanings previously ascribed tothem. The moieties of the formula (II) given above are the residue afterreaction of the terminal end of the polycarbonate polymer chain with acarboxylic acid of the formula: ##STR6## R₁, R₂ and R₃ have the meaningsascribed to them above; or the corresponding acyl halide. Compounds ofthe formula (III) and the corresponding acyl halides are well knowncompounds as are methods of their preparation. Representative of thecompounds of formula (III) are phenoxyacetic acid, 4-chlorophenoxyaceticacid, 2,4-dichlorophenoxyacetic acid, 2,4,6-trichlorophenoxyacetic acid,4-methylphenoxyacetic acid, 3,5-dimethylphenoxyacetic acid,4-p-tert-butylphenoxyacetic acid, 3-octylphenoxyacetic acid,4-phenylphenoxyacetic acid, 4-(p-chlorophenyl)-phenoxyacetic acid,4-p-cumylphenoxyacetic acid, naphthoxy- acetic acid and the like. Thecorresponding acyl halides may be prepared by acylation of the acid offormula (III) using known methods; see for example the method of Clokeet al., JACS 53, 2794 (1931).

The novel carbonate polymers of the instant invention are prepared byreacting at least one compound of Formula (III) or the correspondingacyl halide with a dihydric phenol and a carbonate precursor. During thepolymerization reaction the compounds of Formula (III) react with thedihydric phenol to form the end groups present in the polymer.

Only one compound of Formula III may be used, in which case all of theend groups on the polymers will be the same, or two or more differentcompounds of Formula III may be used in conjunction with known phenoland tertiary butylphenol chain terminators. In such instance thepolymers will contain a mixture of end groups formed by the reaction ofthe various end capping agents with the polymer. The amount of theparticular end capping agent used is determinative of the ratio of theresultant end groups present in the polymer.

The method for preparing the aromatic carbonate polymer of thisinvention, when employing phosgene, involves passing phosgene into areaction mixture containing a dihydric phenol, an acid acceptor, and atleast one compound of Formula III. The compound of Formula III can bepresent before the introduction of the phosgene or it may be added afterintroduction of the phosgene has commenced.

A suitable acid acceptor may be either organic or inorganic in nature.Representative of an organic acid acceptor is a tertiary amine such aspyridine, triethylamine, dimethylaniline, tributylamine and the like.The inorganic acid acceptor may be one which can be either a hydroxide,a carbonate, a bicarbonate, or a phosphate or an alkali or alkalineearth metal hydroxide. Also present in the reaction mixture may be acatalyst. The catalysts which are employed herein can be any of thecatalysts that aid the polymerization of bisphenol A with phosgene.Representative catalysts include tertiary amines, secondary amines,quaternary ammonium compounds, quaternary phosphonium compounds,amidines and the like.

The temperature at which the phosgenation reaction proceeds may varyfrom below 0° C. to above 100° C. The reaction proceeds satisfactorilyat temperatures from room temperature (25° C.) to 50° C. Since thereaction is exothermic, the rate of phosgene addition may be used tocontrol the reaction temperature. The amount of the phosgene requiredwill generally depend upon the amount of the dihydric phenol present.Generally speaking, one mole of phosgene will react with one mole of thedihydric phenol to provide the polymer and two moles of HCI. Two molesof HCI are in turn "attached" by the acid acceptor present. Theforegoing are herein referred to as stoichiometric or theoreticalamounts.

A feature of the invention is that the compounds of Formula III reactwith the carbonate polymer to provide a polycarbonate having improvedprocessing properties (low-or no-plate-out) The weight average molecularweight, for example, can be controlled between about 1,000 and about200,000 depending upon the amount of the compound of Formula IIIemployed. Generally, the greater the amount of the compound of FormulaIII employed in the reaction mixture the lower the molecular weight ofthe carbonate polymer. Conversely, the smaller the amount of thecompound of Formula III employed the larger the molecular weight of thepolycarbonate. The amount of the compound of the formula (III) employedis a terminating amount. By terminating amount is meant an amounteffective to terminate the chain length of the carbonate polymer beforethe molecular weight of the polymer becomes too high and, consequently,the polymer becomes too viscous for any practical application, butinsufficient to terminate the polymer chain before a polycarbonate ofuseful molecular weight is formed. Generally, this amount ranges frombetween about 1 to about 10 mole percent based on the amount of thedihydric phenol present, preferably from about 1 to 7 mole%.

The following examples and preparations describe the manner and processof making and using the invention and set forth the best modecontemplated by the inventor of carrying out the invention but are notto be construed as limiting the invention. Where reported, the followingtests were carried out.

Intrinsic Viscosity (I.V.)

The intrinsic viscosity was measured at a temperature of 25° C. inchloroform and is reported in deciliters/gram (dl/g).

Plate-Out

Plate-out is determined with the assistance of Fourier TransformInfra-red Spectroscopy (FTIR). The procedures consists of placing 2.6grams of the polymer being examined in a vial. A silver chloride FTIRslide is placed over the mouth of the vial, which is then placed in theconfines of a hot steel block (temperature 340° ) having a depth of 2.54cm., for 8 minutes. Plate-out, if any, condenses on the silver chlorideslide, for reading by the aforesaid spectroscopic technique and aregiven by weight.

Molecular Weight (Mw) and Number (Mn)

The weight average molecular weight (Mw) and number average molecularnumber (Mn) were determined by gel permeation chromatography (GPC) inchloroform relative to polystyrene standards using a UV detector at 254nm.

KASHA INDEX (KI):

The KI of a resin is a measurement of its melt viscosity and is obtainedin the following manner: a film of the resin is pressed at 550° C. andprovided. Seven grams of film resin, dried a minimum of 90 minutes at125° C., are added to a modified Tinius-Olsen model T3 melt indexer; thetemperature in the indexer is maintained at 250° C. and the resin isheated at this temperature for 6 or 12 minutes, after 6 or 12 minutesthe resin is forced through a 0.04125 inch radius orifice using aplunger of radius 0.1865 inch and an applied force of 17.7lbs.; the timerequired for the plunger to travel two inches is measured incentiseconds; that is reported as the KI.

Glass Transition Temperature (Tg):

The glass transition temperatures were determined by using aPerkin-Elmer DSC-2B instrument which measures the glass transitiontemperature or (Tg) by differential scanning calorimetry.

EXAMPLE 1

This example illustrates a polycarbonate end-capped with a prior artcompound and thus falling outside the scope of the present invention.

To a reactor fitted with a mechanical agitator are charged 450 ml ofdeionized water, 600 ml of methylene chloride, 91.3 grams (0.40 moles)of bisphenol A, 1 milliliter of triethylamine, and 4.42 gms (0.02 moles)of p-tert-butyl-phenol (5 mol%). Phosgene is introduced at the rate of1.25 g/min. and phosgenation is continued for 34 minutes. The pH ismaintained at between 10.5 and 11.5 by the addition of 25% aqueoussodium hydroxide. After phosgenation has ceased, the mixture is stirredfor 10 minutes at a pH of 11 and then the brine layer is separated bycentrifuge and the resin solution is washed with aqueous acid and water.The resin is precipitated in hot water and dried at a temperature of125° C.

EXAMPLE 2

The procedure of Example 1, supra., is repeated except that thep-tert-butylphenol as used therein is replaced with 5.3 mol% of2,4-dichlorophenoxyacetic acid. The polymer is characterized by an I.V.of 0.394 dl/g; a K.I. of 4,446; a Tg of 139° C.; a Mw of 36,000 and a Mnof 6000. Representative samples of the polymers obtained in each ofExamples 1 and 2 were tested for plate-out. The end-capped polycarbonateof Example 2 did not exhibit any plate-out. The phenol cappedpolycarbonate of Example 1 afforded 0.01 mg of plate-out/g of polymer;the plate-out was shown by FTIR to be the diaryl carbonate.

EXAMPLE 3

The procedure of Example 1, supra., is repeated except that thep-tert-butylphenol as used therein is replaced with 2.8 mol% of2,4-di-t-butylphenoxyacetic acid. The polymer is characterized by an IVof 0.63 dl/g; a Tg of 152° C.; a Mw of 66,800 and a Mn of 14,600.

EXAMPLE 4

The procedure of Example 1, supra., is repeated except that thep-tert-butylphenol as used therein is replaced with 2.8 mol% of3,5-di-t-butylphenoxyacetic acid. The polymer is characterized by an IVof 0.52 dl/g; a Tg of 147° C.; a Mw of 56,300 and a Mn of 13,800.

EXAMPLE 5

The procedure of Example 1, supra., is repeated except that thep-tert-buytlphenol as used therein is replaced with 2.8 mol% of2,4-dicumylphenoxyacetic acid. The polymer is characterized by an IV of0.55 dl/g; a Tg of 146° C.; a Mw of 58,200 and a Mn of 13,600.

EXAMPLE 6 Preparation of 2,4-dicumylphenoxyacetic acid

In a 500 ml three neck flask equipped with mechanical stirrer, nitrogeninlet and Dean-Stark trap/ condenser was added 40.0 grams (0.121 moles)2,4-dicumylphenol, 150 ml dimethylsulfoxide (DMSO), 0.121 moles ofsodium hydroxide (9.68 grams of 50% aqueous NaOH), and 100 ml toluene.The mixture is stirred and heated to azeotropically remove water. Afterwater removal is complete the temperature is lowered to about 90° C. and14.10 grams (0.121 moles) of the sodium salt of chloroacetic acid isadded. The reaction is stirred at 90° C. for 16 hours. The product isisolated by cooling and pouring the reaction mixture into 500 ml of a 2%aqueous hydrochloric acid. After filtration, washing with water anddrying a white powder was obtained which exhibited a melting point of114° C.

EXAMPLE 7 Preparation of 2,4-di-tert-butylphenoxyacetic acid

Following the procedure for 2,4-di-cumylphenoxyacetic acid given above,except employing 40.0 grams (0.194 moles) 2,4-di-tert-butyl phenol;0.194 moles sodium hydroxide; and 22.58 grams (0.194 moles) sodium saltchloroacetic acid, there is obtained after isolation and crystallizationfrom toluene a material exhibiting a melting point of 175° C. and 100%relative purity by gas chromatography.

EXAMPLE 8 Preparation of 3,5-di-tert-butylohenoxyacetic acid

Following the procedure for 2,4-dicumylphenoxyacetic acid given aboveexcept using; 30.10 grams (0.146 moles) 3,5-di-tert-butylphenol; 0.146moles sodium hydroxide; and 17.0 grams (0.146 moles) sodium salt ofchloroacetic there is obtained a product which upon isolation gave awhite powder exhibiting a melting point of 134° C. and 99.6% relativepurity by gas chromatography.

What is claimed is:
 1. The compound 2,4-di-cumylphenoxyacetic acid. 2.The compound 2,4-di-tert-butylphenoxyacetic acid.